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Characterization of Rare-Earth Doped Thermal Barrier Coatings for Phosphor Thermometry

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Characterization of Rare-Earth Doped Thermal Barrier Coatings for Phosphor Thermometry University of Central Florida STARS Electronic Theses and Dissertations, 2004-2019 2019 Characterization of Rare-earth Doped Thermal Barrier Coatings for Phosphor Thermometry Quentin Fouliard University of Central Florida Part of the Aerospace Engineering Commons Find similar works at: https://stars.library.ucf.edu/etd University of Central Florida Libraries http://library.ucf.edu This Doctoral Dissertation (Open Access) is brought to you for free and open access by STARS. It has been accepted for inclusion in Electronic Theses and Dissertations, 2004-2019 by an authorized administrator of STARS. For more information, please contact [email protected]. STARS Citation Fouliard, Quentin, "Characterization of Rare-earth Doped Thermal Barrier Coatings for Phosphor Thermometry" (2019). Electronic Theses and Dissertations, 2004-2019. 6869. https://stars.library.ucf.edu/etd/6869 CHARACTERIZATION OF RARE-EARTH DOPED THERMAL BARRIER COATINGS FOR PHOSPHOR THERMOMETRY by QUENTIN FOULIARD B.S. Ecole´ Polytechnique de l’Universite´ de Nantes, 2014 M.S. Ecole´ Polytechnique de l’Universite´ de Nantes, 2016 A dissertation submitted in partial fulfillment of the requirements for the degree of Doctor of Philosophy in the Department of Mechanical and Aerospace Engineering in the College of Engineering and Computer Science at the University of Central Florida Orlando, Florida Fall Term 2019 Major Professor: Seetha Raghavan c 2019 Quentin Fouliard ii ABSTRACT Thermal Barrier Coatings have been extensively used to protect and insulate the metal- lic components in turbine engines from extreme environments to achieve higher turbine inlet temperatures, resulting in an increase in combined engine cycle efficiency, lower- ing NOx emissions and fuel consumption. Additionally, as the major failure mechanisms determining lifetime are thermally activated during engine operation, uncertainty in tem- perature measurements affects lifetime prediction. Early detection of Thermal Barrier Coatings spallation symptoms, associated with local delamination induced temperature changes, can reduce forced engine outages. Further improvements are envisioned with the development of more reliable measurement techniques. For this purpose, Phosphor Thermometry has been considered a promising method for precision monitoring of tur- bine blade coatings that contain embedded phosphor dopants. In this work, a modified four-flux Kubelka-Munk model for luminescent rare-earth doped Thermal Barrier Coat- ing configurations supported the design and the fabrication of viable sensing coatings for potential industrial implementation. Phosphor Thermometry instrumentation was devel- oped with the objective of expanding capabilities of the technique, using a synchronized iii acquisition method on sensing coatings. Experiments on an innovative Erbium-Europium co-doped Yttria-Stabilized Zirconia coating have demonstrated the effectiveness of this advanced Phosphor Thermometry instrument with enhanced sensitivity and extended tem- perature range. Delamination progression monitoring was achieved for the first time using a Thermal Barrier Coating configuration subjected to indentation that includes a thin lumi- nescent layer deposited on the surface and associating the multi-layer configuration with a predictive model that evaluates the advancement of the degradation of the coatings. To further ensure the integrity of the phosphor doped coatings, synchrotron X-ray diffrac- tion was performed to characterize the specific residual strains and thermal expansion of the materials, determining mechanical robustness and compatibility with state-of-the-art Thermal Barrier Coatings. The outcomes of this work pave the way for in-situ temperature measurements on phosphor-doped turbine blade coatings with increased performance and accuracy. iv This dissertation is dedicated to my grand parents who always believed that I could accomplish my biggest dreams. I will remember you forever. v ACKNOWLEDGMENTS This dissertation is the product of the excellent support and guidance provided by my advisor, Dr. Seetha Raghavan. I would like to thank you for the experience and the great opportunities: Ambition, dedication and energy are the keys for success. My great recognition goes to Dr. Ranajay Ghosh, for the exceptional skills and for the valuable advice that you shared with me during my Ph.D. My sincere acknowledgments to Dr. Raj Vaidyanathan and Dr. Axel Schulzgen¨ for being part of my committee. My appreciation to the U.S. Department of Energy, National Energy Technology Lab- oratory, University Turbine Systems Research (UTSR): DE-FE00312282, for the financial support which gave me the chance to lead fascinating projects and high-impact research work throughout my entire Ph.D. I would like to ackowledge my industry collaborators: Dr. Bauke Heeg (Lumium), for the great expertise with the instrumentation; Dr. Jeffrey Eldridge (NASA Glenn) and Dr. Douglas Wolfe (Penn State University) for the procurement of lumienscent samples to assess the developed models; Dr. Ramesh Subramanian (Siemens Energy) for the dis- cussions and materials; Dr. Ed Hoffmann (GE aviation) and Joshua Salisbury (GE Global vi Research) for the excellent support and guidance; Dr. Mary McCay, Frank Accornero and David Moreno (FIT Applied Research Laboratory) for the amazing help in the complex manufacturing process; Dr. Jonathan Almer and Dr. Jun Sang-Park (Argonne National Laboratory) for the valuable assistance with synchrotron experiments. A special word to my friend, Dr. Alejandro Carrasco, for the inspiration and uncon- ditional friendship. A particular attention to Estefania Bohorquez, for the caring and the strength that you gave me along the way. A huge thank you to Johnathan Hernandez, Matthew Northam, Valentin Baudrier, Corentin Piveteau, Pierre-Alexandre Jan, Manon Guyon and Muriel Talour for your encouragements during this journey. This herculean work would have been way more tedious without you all. Finally, my greatest gratitude goes to my loving family, for your inestimable support, despite the distance, over the past few years. vii TABLE OF CONTENTS LIST OF FIGURES :::::::::::::::::::::::::::::::::::::::::::::::: xiv LIST OF TABLES ::::::::::::::::::::::::::::::::::::::::::::::::: xxiii CHAPTER 1 : THERMAL BARRIER COATINGS ::::::::::::::::::::::: 1 1.1 Introduction . .1 1.1.1 Purpose and benefits . .1 1.1.2 General structure of TBCs . .3 1.2 Main materials and methods . .5 1.2.1 Standard materials . .5 1.2.2 Air Plasma Spray (APS) . .6 1.2.3 Electron Beam Physical Vapor Deposition (EB-PVD) . .8 1.2.4 Thermomechanical properties . 11 1.3 Thermally activated degradation mechanisms . 12 viii 1.3.1 Temperature effects on TGO growth . 12 1.3.2 Phase stability of YSZ . 13 1.4 Motivations for accurate temperature measurements on TBCs . 14 1.4.1 Possible efficiency improvements . 14 1.4.2 Enhanced lifetime monitoring of coatings . 14 1.4.3 Temperature measurement techniques for TBCs . 15 CHAPTER 2 : PHOSPHOR THERMOMETRY FOR TEMPERATURE MONI- TORING OF THERMAL BARRIER COATINGS ::::::::::::::::::::::::: 20 2.1 Phosphor configurations . 23 2.1.1 Rare-earth doped Yttrium Aluminum garnet (Y3Al5O12:RE) . 23 2.1.2 Rare-earth doped Yttrium oxide (Y2O3:RE) . 24 2.1.3 Rare-earth doped Yttria stabilized zirconia (YSZ:RE) . 25 2.2 Effects of dopant concentration . 26 2.3 Rare-earth doped layer stability in ceramic coatings . 28 2.4 Data acquisition methods . 32 2.4.1 Lifetime decay method . 32 2.4.2 Intensity ratio method . 34 ix 2.5 Motivations for preliminary predictive models . 35 CHAPTER 3 : LUMINESCENCE MODELING AND RESULTS :::::::::::: 36 3.1 Luminescence intensity in doped coatings . 36 3.2 Location of temperature-dependent luminescence . 48 3.3 Model sensitivity to thermal parameters . 59 3.4 Delamination progression modeling . 63 3.5 Conclusions of the chapter . 79 CHAPTER 4 : MANUFACTURING OF RARE-EARTH DOPED THERMAL BARRIER COATING CONFIGURATIONS ::::::::::::::::::::::::::::: 85 4.1 Fabrication of rare-earth doped YSZ samples . 85 4.2 An innovative configuration: Doped bond coat for TGO sensing . 90 4.3 Luminescence characterization an Erbium doped bond coat configuration . 93 4.4 Elemental mapping of Dysprosium and Erbium doped bond coat configu- rations . 95 CHAPTER 5 : PHOSPHOR THERMOMETRY INSTRUMENTATION AND EX- PERIMENTATION :::::::::::::::::::::::::::::::::::::::::::::::: 97 x 5.1 Context of instrumentation development . 97 5.2 Development of the instrumentation . 99 5.3 Phosphor Thermometry system characteristics . 100 5.3.1 General specifications of the instrument . 100 5.3.2 Testing of the detectors . 101 5.3.3 Optical setup for YSZ:Er,Eu temperature sensing . 104 5.3.4 High temperature setup with an induction heating system . 107 5.3.5 Control of the temperature using infrared thermometry . 108 5.3.6 Data collection . 109 5.4 Results and discussions . 115 5.4.1 Temporal analysis . 115 5.4.2 Intensity considerations . 117 5.4.3 Measurement error considerations . 119 5.4.4 Outcomes of the developed instrumentation for YSZ:Er,Eu TBC sensing . 121 5.4.5 Initial effort for model-validation through high heat-flux experi- mentation . 122 xi CHAPTER 6 : EVALUATION OF RARE-EARTH DOPED TBC CONFIGURA- TIONS USING SYNCHROTRON RADIATION :::::::::::::::::::::::::: 129 6.1 Synchrotron X-Ray Diffraction theory . 129 6.2 Transmission X-ray diffraction for TBCs . 131 6.3 XRD experiment setup and parameters . 132 6.3.1 Experiment parameters . 132 6.3.2 Sample description . 133 6.3.3 Sample setup . 133 6.3.4 Replication of high temperature engine environments
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